Treatment of engine exhaust using molecular sieve SSZ-74

This application claims the benefit under 35 USC 119 of Provisional Application No. 60/754,858, filed Dec. 28, 2005.

BACKGROUND OF THE INVENTION

Field of the Invention

Gaseous waste products resulting from the combustion of hydrocarbonaceous fuels, such as gasoline and fuel oils, comprise carbon monoxide, hydrocarbons and nitrogen oxides as products of combustion or incomplete combustion, and pose a serious health problem with respect to pollution of the atmosphere. While exhaust gases from other carbonaceous fuel-burning sources, such as stationary engines, industrial furnaces, etc., contribute substantially to air pollution, the exhaust gases from automotive engines are a principal source of pollution. Because of these health problem concerns, the Environmental Protection Agency (EPA) has promulgated strict controls on the amounts of carbon monoxide, hydrocarbons and nitrogen oxides which automobiles can emit. The implementation of these controls has resulted in the use of catalytic converters to reduce the amount of pollutants emitted from automobiles.

In order to achieve the simultaneous conversion of carbon monoxide, hydrocarbon and nitrogen oxide pollutants, it has become the practice to employ catalysts in conjunction with air-to-fuel ratio control means which functions in response to a feedback signal from an oxygen sensor in the engine exhaust system. Although these three component control catalysts work quite well after they have reached operating temperature of about 300° C., at lower temperatures they are not able to convert substantial amounts of the pollutants. What this means is that when an engine and in particular an automobile engine is started up, the three component control catalyst is not able to convert the hydrocarbons and other pollutants to innocuous compounds.

Adsorbent beds have been used to adsorb the hydrocarbons during the cold start portion of the engine. Although the process typically will be used with hydrocarbon fuels, the instant invention can also be used to treat exhaust streams from alcohol fueled engines. The adsorbent bed is typically placed immediately before the catalyst. Thus, the exhaust stream is first flowed through the adsorbent bed and then through the catalyst, The adsorbent bed preferentially adsorbs hydrocarbons over water under the conditions present in the exhaust stream. After a certain amount of time, the adsorbent bed, has reached a temperature (typically about 150° C.) at which the bed is no longer able to remove hydrocarbons from the exhaust stream. That is, hydrocarbons are actually desorbed from the adsorbent bed instead of being adsorbed. This regenerates the adsorbent bed so that it can adsorb hydrocarbons during a subsequent cold start.

The prior art reveals several references dealing with the use of adsorbent beds to minimize hydrocarbon emissions during a cold start engine operation. One such reference is U.S. Pat. No. 3,699,683 in which an adsorbent bed is placed after both a reducing catalyst and an oxidizing catalyst. The patentees disclose that when the exhaust gas stream is below 200° C. the gas stream is flowed through the reducing catalyst then through the oxidizing catalyst and finally through the adsorbent beds thereby adsorbing hydrocarbons on the adsorbent bed. When the temperature goes above 200° C. the gas stream which is discharged from the oxidation catalyst is divided into a major and minor portion, the major portion being discharged directly into the atmosphere and the minor portion passing through the adsorbent bed whereby unburned hydrocarbon is desorbed and then flowing the resulting minor portion of this exhaust stream containing the desorbed unburned hydrocarbons into the engine where they are burned.

Another reference is U.S. Pat. No. 2,942,932 which teaches a process for oxidizing carbon monoxide and hydrocarbons which are contained in exhaust gas streams. The process disclosed in this patent consists of flowing an exhaust stream which is below 800° F. into an adsorption zone which adsorbs the carbon monoxide and hydrocarbons and then passing the resultant stream from this adsorption zone into an oxidation zone. When the temperature of the exhaust gas stream reaches about 800° F. the exhaust stream is no longer passed through the adsorption zone but is passed directly to the oxidation zone with the addition of excess air.

U.S. Pat. No. 5,078,979, issued Jan. 7, 1992 to Dunne, which is incorporated herein by reference in its entirety discloses treating an exhaust gas stream from an engine to prevent cold start emissions using a molecular sieve adsorbent bed. Examples of the molecular sieve include faujasites, clinoptilolites, mordenites, chabazite, silicalite, zeolite Y, ultrastable zeolite Y, and ZSM-5.

Canadian Patent No. 1,205,980 discloses a method of reducing exhaust emissions from an alcohol fueled automotive vehicle. This method consists of directing the cool engine startup exhaust gas through a bed of zeolite particles and then over an oxidation catalyst and then the gas is discharged to the atmosphere. As the exhaust gas stream warms up it is continuously passed over the adsorption bed and then over the oxidation bed.

SUMMARY OF THE INVENTION

This invention generally relates to a process for treating an engine exhaust stream and in particular to a process for minimizing emissions during the cold start operation of an engine. Accordingly, the present invention provides a process for treating a cold-start engine exhaust gas stream containing hydrocarbons and other pollutants consisting of flowing said engine exhaust gas stream over a molecular sieve bed which preferentially adsorbs the hydrocarbons over water to provide a first exhaust stream, and flowing the first exhaust gas stream over a catalyst to convert any residual hydrocarbons and other pollutants contained in the first exhaust gas stream to innocuous products and provide a treated exhaust stream and discharging the treated exhaust stream into the atmosphere, the molecular sieve bed characterized in that it comprises a crystalline molecular sieve having a mole ratio greater than about 15 of (1) an oxide of a first tetravalent element to (2) an oxide of a trivalent element, pentavalent element, second tetravalent element which is different from said first tetravalent element or mixture thereof and having, after calcination, the X-ray diffraction lines of Table II. It should be noted that the phrase “mole ratio greater than about 15” includes the case where there is no oxide (2), i.e., the mole ratio of oxide (1) to oxide (2) is infinity. In that case the molecular sieve is comprised of essentially all silicon oxide.

Also provided in accordance with the present invention is such a process wherein the molecular sieve crystalline molecular sieve has a mole ratio greater than about 15 of (1) silicon oxide to (2) an oxide selected from aluminum oxide, gallium oxide, iron oxide, boron oxide, titanium oxide, indium oxide and mixtures thereof.

The present invention further provides such a process wherein the engine is an internal combustion engine, including automobile engines, which can be fueled by a hydrocarbonaceous fuel.

Also provided by the present invention is such a process wherein the molecular sieve has deposited on it a metal selected from the group consisting Of platinum, palladium, rhodium, ruthenium, and mixtures thereof.

BRIEF DESCRIPTION OF THE DRAWING

<figref idrefs="DRAWINGS">FIG. 1</figref> shows a comparison of two X-ray diffraction patterns, the top one being ZSM-5 and the bottom one being SSZ-74.

DETAILED DESCRIPTION OF THE INVENTION

As stated this invention generally relates to a process for treating an engine exhaust stream and in particular to a process for minimizing emissions during the cold start operation of an engine. The engine consists of any internal or external combustion engine which generates an exhaust gas stream containing noxious components or pollutants including unburned or thermally degraded hydrocarbons or similar organics. Other noxious components usually present in the exhaust gas include nitrogen oxides and carbon monoxide. The engine may be fueled by a hydrocarbonaceous fuel. As used in this specification and in the appended claims, the term “hydrocarbonaceous fuel” includes hydrocarbons, alcohols and mixtures thereof. Examples of hydrocarbons which can be used to fuel the engine are the mixtures of hydrocarbons which make up gasoline or diesel fuel. The alcohols which may be used to fuel engines include ethanol and methanol. Mixtures of alcohols and mixtures of alcohols and hydrocarbons can also be used. The engine may be a jet engine, gas turbine, internal combustion engine, such as an automobile, truck or bus engine, a diesel engine or the like. The process of this invention is particularly suited for hydrocarbon, alcohol, or hydrocarbon-alcohol mixture, internal combustion engine mounted in an automobile. For convenience the description will use hydrocarbon as the fuel to exemplify the invention. The use of hydrocarbon in the subsequent description is not to be construed as limiting the invention to hydrocarbon fueled engines.

When the engine is started up, it produces a relatively high concentration of hydrocarbons in the engine exhaust gas stream as well as other pollutants. Pollutants will be used herein to collectively refer to any unburned fuel components and combustion byproducts found in the exhaust stream. For example, when the fuel is a hydrocarbon fuel, hydrocarbons, nitrogen oxides, carbon monoxide and other combustion byproducts will be found in the engine exhaust gas stream. The temperature of this engine exhaust stream is relatively cool, generally below 500° C. and typically in the range of 200° to 400° C. This engine exhaust stream has the above characteristics during the initial period of engine operation, typically for the first 30 to 120 seconds after startup of a cold engine. The engine exhaust stream will typically contain, by volume, about 500 to 1000 ppm hydrocarbons.

The engine exhaust gas stream which is to be treated is flowed over a molecular sieve bed comprising molecular sieve SSZ-56 a first exhaust stream. Molecular sieve SSZ-56 is described below. The first exhaust stream which is discharged from the molecular sieve bed is now flowed over a catalyst to convert the pollutants contained in the first exhaust stream to innocuous components and provide a treated exhaust stream which is discharged into the atmosphere. It is understood that prior to discharge into the atmosphere, the treated exhaust stream may be flowed through a muffler or other sound reduction apparatus well known in the art.

The catalyst which is used to convert the pollutants to innocuous components is usually referred to in the art as a three-component control catalyst because it can simultaneously oxidize any residual hydrocarbons present in the first exhaust stream to carbon dioxide and water, oxidize any residual carbon monoxide to carbon dioxide and reduce any residual nitric oxide to nitrogen and oxygen. In some cases the catalyst may not be required to convert nitric oxide to nitrogen and oxygen, e.g., when an alcohol is used as the fuel. In this case the catalyst is called an oxidation catalyst. Because of the relatively low temperature of the engine exhaust stream and the first exhaust stream, this catalyst does not function at a very high efficiency, thereby necessitating the molecular sieve bed.

When the molecular sieve bed reaches a sufficient temperature, typically about 150-200° C., the pollutants which are adsorbed in the bed begin to desorb and are carried by the first exhaust stream over the catalyst At this point the catalyst has reached its operating temperature and is therefore capable of fully converting the pollutants to innocuous components.

The adsorbent bed used in the instant invention can be conveniently employed in particulate form or the adsorbent can be deposited onto a solid monolithic carrier. When particulate form is desired, the adsorbent can be formed into shapes such as pills, pellets, granules, rings, spheres, etc. In the employment of a monolithic form, it is usually most convenient to employ the adsorbent as a thin film or coating deposited on an inert carrier material which provides the structural support for the adsorbent. The inert carrier material can be any refractory material such as ceramic or metallic materials. It is desirable that the carrier material be unreactive with the adsorbent and not be degraded by the gas to which it is exposed. Examples of suitable ceramic materials include sillimanite, petalite, cordierite, mullite, zircon, zircon mullite, spondumene, alumina-titanate, etc. Additionally, metallic materials which are within the scope of this invention include metals and alloys as disclosed in U.S. Pat. No. 3,920,583 which are oxidation resistant and are otherwise capable of withstanding high temperatures.

The carrier material can best be utilized in any rigid unitary configuration which provides a plurality of pores or channels extending in the direction of gas flow. It is preferred that the configuration be a honeycomb configuration. The honeycomb structure can be used advantageously in either unitary form, or as an arrangement of multiple modules. The honeycomb structure is usually oriented such that gas flow is generally in the same direction as the cells or channels of the honeycomb structure. For a more detailed discussion of monolithic structures, refer to U.S. Pat. Nos. 3,785,998 and 3,767,453.

The molecular sieve is deposited onto the carrier by any convenient way well known in the art. A preferred method involves preparing a slurry using the molecular sieve and coating the monolithic honeycomb carrier with the slurry. The slurry can be prepared by means known in the art such as combining the appropriate amount of the molecular sieve and a binder with water. This mixture is then blended by using means such as sonification, milling, etc. This slurry is used to coat a monolithic honeycomb by dipping the honeycomb into the slurry, removing the excess slurry by draining or blowing out the channels, and heating to about 100° C. If the desired loading of molecular sieve is not achieved, the above process may be repeated as many times as required to achieve the desired loading.

Instead of depositing the molecular sieve onto a monolithic honeycomb structure, one can take the molecular sieve and form it into a monolithic honeycomb structure by means known in the art.

The adsorbent may optionally contain one or more catalytic metals dispersed thereon. The metals which can be dispersed on the adsorbent are the noble metals which consist of platinum, palladium, rhodium, ruthenium, and mixtures thereof. The desired noble metal may be deposited onto the adsorbent, which acts as a support, in any suitable manner well known in the art. One example of a method of dispersing the noble metal onto the adsorbent support involves impregnating the adsorbent support with an aqueous solution of a decomposable compound of the desired noble metal or metals, drying the adsorbent which has the noble metal compound dispersed on it and then calcining in air at a temperature of about 400° to about 500° C. for a time of about 1 to about 4 hours. By decomposable compound is meant a compound which upon heating in air gives the metal or metal oxide. Examples of the decomposable compounds which can be used are set forth in U.S. Pat. No. 4,791,091 which is incorporated by reference. Preferred decomposable compounds are chloroplatinic acid, rhodium trichloride, chloropalladic acid, hexachloroiridate (IV) acid and hexachlororuthenate. It is preferable that the noble metal be present in an amount ranging from about 0.01 to about 4 weight percent of the adsorbent support. Specifically, in the case of platinum and palladium the range is 0.1 to 4 weight percent, while in the case of rhodium and ruthenium the range is from about 0.01 to 2 weight percent.

These catalytic metals are capable of oxidizing the hydrocarbon and carbon monoxide and reducing the nitric oxide components to innocuous products. Accordingly, the adsorbent bed can act both as an adsorbent and as a catalyst.

The catalyst which is used in this invention is selected from any three component control or oxidation catalyst well known in the art. Examples of catalysts are those described in U.S. Pat. Nos. 4,528,279; 4,791,091; 4,760,044; 4,868,148; and 4,868,149, which are all incorporated by reference. Preferred catalysts well known in the art are those that contain platinum and rhodium and optionally palladium, while oxidation catalysts usually do not contain rhodium. Oxidation catalysts usually contain platinum and/or palladium metal. These catalysts may also contain promoters and stabilizers such as barium, cerium, lanthanum, nickel, and iron. The noble metals promoters and stabilizers are usually deposited on a support such as alumina, silica, titania, zirconia, alumino silicates, and mixtures thereof with alumina being preferred. The catalyst can be conveniently employed in particulate form or the catalytic composite can be deposited on a solid monolithic carrier with a monolithic carrier being preferred. The particulate form and monolithic form of the catalyst are prepared as described for the adsorbent above.

The molecular sieve used in the adsorbent bed, SSZ-74, comprises a crystalline molecular sieve having a mole ratio greater than about 15 of (1) an oxide of a first tetravalent element to (2) an oxide of a trivalent element, pentavalent element, second tetravalent element which is different from said first tetravalent element or mixture thereof and having, after calcination, the X-ray diffraction lines of Table II.

In preparing SSZ-74, a hexamethylene-1,6-bis-(N-methyl-N-pyrrolidinium) dication is used as a structure directing agent (“SDA”), also known as a crystallization template. The SDA useful for making SSZ-74 has the following structure:

<chemistry id="CHEM-US-00001" num="00001"><img id="EMI-C00001" he="9.65mm" wi="46.74mm" file="US07762059-20100727-C00001.TIF" alt="embedded image" img-content="chem" img-format="tif" /><attachments><attachment idref="CHEM-US-00001" attachment-type="cdx" file="US07762059-20100727-C00001.CDX" /><attachment idref="CHEM-US-00001" attachment-type="mol" file="US07762059-20100727-C00001.MOL" /></attachments></chemistry>

Hexamethylene-1,6-bis-(N-methyl-N-pyrrolidinium) dication

The SDA dication is associated with anions (X⁻) which may be any anion that is not detrimental to the formation of the SSZ-74. Representative anions include halogen, e.g., fluoride, chloride, bromide and iodide, hydroxide, acetate, sulfate, tetrafluoroborate, carboxylate, and the like. Hydroxide is the most preferred anion. The structure directing agent (SDA) may be used to provide hydroxide ion. Thus, it is beneficial to ion exchange, for example, a halide to hydroxide ion.

In general, SSZ-74 is prepared by contacting (1) an active source(s) of silicon oxide, and, optionally, (2) an active source(s) of aluminum oxide, gallium oxide, iron oxide, boron oxide, titanium oxide, indium oxide and mixtures thereof with the hexamethylene-1,6-bis-(N-methyl-N-pyrrolidinium) dication SDA in the presence of fluoride ion.

SSZ-74 is prepared from a reaction mixture comprising, in terms of mole ratios, the following:

<tables id="TABLE-US-00001" num="00001"><table frame="none" colsep="0" rowsep="0"><tgroup align="left" colsep="0" rowsep="0" cols="1"><colspec colname="1" colwidth="217pt" align="center" /><thead><row><entry namest="1" nameend="1" rowsep="1">TABLE A</entry></row></thead><tbody valign="top"><row><entry namest="1" nameend="1" align="center" rowsep="1" /></row><row><entry>Reaction Mixture</entry></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="offset" colwidth="77pt" align="left" /><colspec colname="1" colwidth="49pt" align="center" /><colspec colname="2" colwidth="91pt" align="center" /><tbody valign="top"><row><entry /><entry>Typical</entry><entry>Preferred</entry></row><row><entry /><entry namest="offset" nameend="2" align="center" rowsep="1" /></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="4"><colspec colname="offset" colwidth="21pt" align="left" /><colspec colname="1" colwidth="56pt" align="left" /><colspec colname="2" colwidth="49pt" align="center" /><colspec colname="3" colwidth="91pt" align="center" /><tbody valign="top"><row><entry /><entry>SiO₂/X_aO_b</entry><entry>100 and greater</entry><entry /></row><row><entry /><entry>OH-/SiO₂</entry><entry>0.20-0.80</entry><entry>0.40- 0.60</entry></row><row><entry /><entry>Q/SiO₂</entry><entry>0.20- 0.80</entry><entry>0.40- 0.60</entry></row><row><entry /><entry>M_2/n/SiO₂</entry><entry>  0-0.04</entry><entry>   0-0.025</entry></row><row><entry /><entry>H₂O/SiO₂</entry><entry> 2-10</entry><entry>3-7</entry></row><row><entry /><entry>HF/SiO₂</entry><entry>0.20- 0.80</entry><entry>0.30- 0.60</entry></row><row><entry /><entry namest="offset" nameend="3" align="center" rowsep="1" /></row></tbody></tgroup></table></tables><br /> where X is aluminum, gallium, iron, boron, titanium, indium and mixtures thereof, a is 1 or 2, b is 2 when a is 1 (i.e., W is tetravalent); b is 3 when a is 2 (i.e., W is trivalent), M is an alkali metal cation, alkaline earth metal cation or mixtures thereof; n is the valence of M (i.e., 1 or 2); Q is a hexamethylene-1,6-bis-(N-methyl-N-pyrrolidinium) dication and F is fluoride.

As noted above, the SiO₂/X_aO_bmole ratio in the reaction mixture is 100 and greater. This means that the SiO₂/X_aO_bmole ratio can be infinity, i.e., there is no X_aO_bin the reaction mixture. This results in a version of SSZ-74 that is essentially all silica. As used herein, “essentially all silicon oxide” or “essentially all-silica” means that the molecular sieve's crystal structure is comprised of only silicon oxide or is comprised of silicon oxide and only trace amounts of other oxides, such as aluminum oxide, which may be introduced as impurities in the source of silicon oxide. However, for the sake of stability of the molecular sieve in the engine exhaust stream, it may be desirable to include sufficient X_aO_bin the reaction mixture (and the subsequent product) to help stabilize the molecular sieve.

A preferred source of silicon oxide is tetraethyl orthosilicate. A preferred source of aluminum oxide is LZ-210 zeolite (a type of Y zeolite).

In practice, SSZ-74 is prepared by a process comprising: <ul><li id="ul0001-0001" num="0000"><ul><li id="ul0002-0001" num="0036">(a) preparing an aqueous solution containing (1) a source(s) of silicon oxide, (2) a source(s) of aluminum oxide, gallium oxide, iron oxide, boron oxide, titanium oxide, indium oxide and mixtures thereof, (3) a source of fluoride ion and (4) a hexamethylene-1,6-bis-(N-methyl-N-pyrrolidinium) dication having an anionic counterion which is not detrimental to the formation of SSZ-74;</li><li id="ul0002-0002" num="0037">(b) maintaining the aqueous solution under conditions sufficient to form crystals of SSZ74; and</li><li id="ul0002-0003" num="0038">(c) recovering the crystals of SSZ-74.</li></ul></li></ul>

The reaction mixture is maintained at an elevated temperature until the crystals of the SSZ-74 are formed. The hydrothermal crystallization is usually conducted under autogenous pressure, at a temperature between 100° C. and 200° C., preferably between 135° C. and 180° C. The crystallization period is typically greater than 1 day and preferably from about 3 days to about 20 days. The molecular sieve may be prepared using mild stirring or agitation.

During the hydrothermal crystallization step, the SSZ-74 crystals can be allowed to nucleate spontaneously from the reaction mixture. The use of SSZ-74 crystals as seed material can be advantageous in decreasing the time necessary for complete crystallization to occur. In addition, seeding can lead to an increased purity of the product obtained by promoting the nucleation and/or formation of SSZ-74 over any undesired phases. When used as seeds, SSZ-74 crystals are added in an amount between 0.1 and 10% of the weight of the first tetravalent element oxide, e.g. silica, used in the reaction mixture.

Once the molecular sieve crystals have formed, the solid product is separated from the reaction mixture by standard mechanical separation techniques such as filtration. The crystals are water-washed and then dried, e.g., at 90° C. to 150° C. for from 8 to 24 hours, to obtain the as-synthesized SSZ74 crystals. The drying step can be performed, at atmospheric pressure or under vacuum.

SSZ-74 as prepared has the X-ray diffraction lines of Table I below. SSZ-74 has a composition, as synthesized (i.e., prior to removal of the SDA from the SSZ-74) and in the anhydrous state, comprising the following (in terms of mole ratios):

<tables id="TABLE-US-00002" num="00002"><table frame="none" colsep="0" rowsep="0"><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="offset" colwidth="42pt" align="left" /><colspec colname="1" colwidth="35pt" align="left" /><colspec colname="2" colwidth="140pt" align="center" /><thead><row><entry /><entry namest="offset" nameend="2" align="center" rowsep="1" /></row></thead><tbody valign="top"><row><entry /><entry>SiO₂/X_cO_d</entry><entry>greater than 100</entry></row><row><entry /><entry>M_2/n/SiO₂</entry><entry>  0-0.03</entry></row><row><entry /><entry>Q/SiO₂</entry><entry>0.30-0.70</entry></row><row><entry /><entry>F/SiO₂</entry><entry>0.30-0.70</entry></row><row><entry /><entry namest="offset" nameend="2" align="center" rowsep="1" /></row></tbody></tgroup></table></tables><br /> wherein X is aluminum, gallium, iron, boron, titanium, indium and mixtures thereof, c is 1 or 2; d is 2 when c is 1 (i.e., W is tetravalent) or d is 3 or 5 when c is 2 (i.e., d is 3 when W is trivalent or 5 when W is pentavalent), M is an alkali metal cation, alkaline earth metal cation or mixtures thereof; n is the valence of M (i.e., 1 or 2); Q is a hexamethylene-1,6-bis-(N-methyl-N-pyrrolidinium) dication and F is fluoride.

SSZ-74 is characterized by its X-ray diffraction pattern. SSZ-74r as-synthesized, has a crystalline structure whose X-ray powder diffraction pattern exhibits the characteristic lines shown in Table I.

<tables id="TABLE-US-00003" num="00003"><table frame="none" colsep="0" rowsep="0"><tgroup align="left" colsep="0" rowsep="0" cols="1"><colspec colname="1" colwidth="217pt" align="center" /><thead><row><entry namest="1" nameend="1" rowsep="1">TABLE I</entry></row></thead><tbody valign="top"><row><entry namest="1" nameend="1" align="center" rowsep="1" /></row><row><entry>As-Synthesized SSZ-74</entry></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="1" colwidth="63pt" align="center" /><colspec colname="2" colwidth="70pt" align="center" /><colspec colname="3" colwidth="84pt" align="center" /><tbody valign="top"><row><entry /><entry /><entry>Relative Integrated</entry></row><row><entry>2 Theta^(a)</entry><entry>d-spacing (Angstroms)</entry><entry>Intensity (%)^(b)</entry></row><row><entry namest="1" nameend="3" align="center" rowsep="1" /></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="1" colwidth="63pt" align="char" char="." /><colspec colname="2" colwidth="70pt" align="char" char="." /><colspec colname="3" colwidth="84pt" align="center" /><tbody valign="top"><row><entry>7.95</entry><entry>11.11</entry><entry>W</entry></row><row><entry>8.68</entry><entry>10.18</entry><entry>M</entry></row><row><entry>8.85</entry><entry>9.98</entry><entry>W-M</entry></row><row><entry>9.02</entry><entry>9.80</entry><entry>W</entry></row><row><entry>22.69</entry><entry>3.92</entry><entry>W-M</entry></row><row><entry>23.14</entry><entry>3.84</entry><entry>VS</entry></row><row><entry>24.01</entry><entry>3.70</entry><entry>M</entry></row><row><entry>24.52</entry><entry>3.63</entry><entry>W</entry></row><row><entry>24.93</entry><entry>3.57</entry><entry>W</entry></row><row><entry>29.95</entry><entry>2.98</entry><entry>W</entry></row><row><entry namest="1" nameend="3" align="center" rowsep="1" /></row><row><entry namest="1" nameend="3" align="left" id="FOO-00001">^(a)± 0.1</entry></row><row><entry namest="1" nameend="3" align="left" id="FOO-00002">^(b)The X-ray patterns provided are based on a relative intensity scale in which the strongest line in the X-ray pattern is assigned a value of 100: W (weak) is less than 20; M (medium) is between 20 and 40; S (strong) is between 40 and 60; VS (very strong) is greater than 60.</entry></row></tbody></tgroup></table></tables>

Table IA below shows the X-ray powder diffraction lines for as-synthesized SSZ-74 including actual relative intensities.

<tables id="TABLE-US-00004" num="00004"><table frame="none" colsep="0" rowsep="0"><tgroup align="left" colsep="0" rowsep="0" cols="1"><colspec colname="1" colwidth="217pt" align="center" /><thead><row><entry namest="1" nameend="1" rowsep="1">TABLE IA</entry></row></thead><tbody valign="top"><row><entry namest="1" nameend="1" align="center" rowsep="1" /></row><row><entry>As-Synthesized SSZ-74</entry></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="1" colwidth="77pt" align="center" /><colspec colname="2" colwidth="70pt" align="center" /><colspec colname="3" colwidth="70pt" align="center" /><tbody valign="top"><row><entry>2 Theta^(a)</entry><entry>d-spacing (Angstroms)</entry><entry>Intensity</entry></row><row><entry namest="1" nameend="3" align="center" rowsep="1" /></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="1" colwidth="77pt" align="char" char="." /><colspec colname="2" colwidth="70pt" align="char" char="." /><colspec colname="3" colwidth="70pt" align="char" char="." /><tbody valign="top"><row><entry>7.95</entry><entry>11.11</entry><entry>7.9</entry></row><row><entry>8.68</entry><entry>10.18</entry><entry>21.1</entry></row><row><entry>8.85</entry><entry>9.98</entry><entry>18.7</entry></row><row><entry>9.02</entry><entry>9.80</entry><entry>11.3</entry></row><row><entry>11.30</entry><entry>7.82</entry><entry>0.4</entry></row><row><entry>12.70</entry><entry>6.96</entry><entry>1.8</entry></row><row><entry>13.98</entry><entry>6.33</entry><entry>2.4</entry></row><row><entry>14.77</entry><entry>5.99</entry><entry>0.5</entry></row><row><entry>14.85</entry><entry>5.96</entry><entry>2.1</entry></row><row><entry>15.93</entry><entry>5.56</entry><entry>6.3</entry></row><row><entry>16.30</entry><entry>5.43</entry><entry>4.6</entry></row><row><entry>16.50</entry><entry>5.37</entry><entry>1.8</entry></row><row><entry>17.05</entry><entry>5.20</entry><entry>0.8</entry></row><row><entry>17.41</entry><entry>5.09</entry><entry>0.1</entry></row><row><entry>17.71</entry><entry>5.00</entry><entry>2.0</entry></row><row><entry>18.09</entry><entry>4.90</entry><entry>7.4</entry></row><row><entry>18.38</entry><entry>4.82</entry><entry>0.7</entry></row><row><entry>18.89</entry><entry>4.69</entry><entry>0.9</entry></row><row><entry>18.96</entry><entry>4.68</entry><entry>4.4</entry></row><row><entry>19.69</entry><entry>4.51</entry><entry>1.8</entry></row><row><entry>20.39</entry><entry>4.35</entry><entry>5.1</entry></row><row><entry>20.63</entry><entry>4.30</entry><entry>4.2</entry></row><row><entry>21.12</entry><entry>4.20</entry><entry>7.7</entry></row><row><entry>21.55</entry><entry>4.12</entry><entry>5.4</entry></row><row><entry>21.75</entry><entry>4.08</entry><entry>0.5</entry></row><row><entry>21.80</entry><entry>4.07</entry><entry>1.4</entry></row><row><entry>21.88</entry><entry>4.06</entry><entry>2.1</entry></row><row><entry>21.96</entry><entry>4.04</entry><entry>1.5</entry></row><row><entry>22.17</entry><entry>4.01</entry><entry>0.8</entry></row><row><entry>22.69</entry><entry>3.92</entry><entry>18.9</entry></row><row><entry>23.14</entry><entry>3.84</entry><entry>100.0</entry></row><row><entry>23.89</entry><entry>3.72</entry><entry>9.4</entry></row><row><entry>24.01</entry><entry>3.70</entry><entry>25.6</entry></row><row><entry>24.52</entry><entry>3.63</entry><entry>13.7</entry></row><row><entry>24.68</entry><entry>3.60</entry><entry>2.1</entry></row><row><entry>24.93</entry><entry>3.57</entry><entry>11.3</entry></row><row><entry>25.09</entry><entry>3.55</entry><entry>0.9</entry></row><row><entry>25.37</entry><entry>3.51</entry><entry>1.7</entry></row><row><entry>25.57</entry><entry>3.48</entry><entry>2.7</entry></row><row><entry>26.20</entry><entry>3.40</entry><entry>5.5</entry></row><row><entry>26.31</entry><entry>3.38</entry><entry>0.8</entry></row><row><entry>26.67</entry><entry>3.34</entry><entry>2.0</entry></row><row><entry>26.76</entry><entry>3.33</entry><entry>1.0</entry></row><row><entry>26.82</entry><entry>3.32</entry><entry>0.9</entry></row><row><entry>27.01</entry><entry>3.30</entry><entry>3.4</entry></row><row><entry>27.05</entry><entry>3.29</entry><entry>0.8</entry></row><row><entry>27.48</entry><entry>3.24</entry><entry>0.8</entry></row><row><entry>27.99</entry><entry>3.19</entry><entry>4.2</entry></row><row><entry>28.15</entry><entry>3.16</entry><entry>0.8</entry></row><row><entry>28.78</entry><entry>3.10</entry><entry>0.6</entry></row><row><entry>29.03</entry><entry>3.07</entry><entry>0.7</entry></row><row><entry>29.31</entry><entry>3.04</entry><entry>0.9</entry></row><row><entry>29.58</entry><entry>3.02</entry><entry>2.4</entry></row><row><entry>29.95</entry><entry>2.98</entry><entry>9.6</entry></row><row><entry>30.44</entry><entry>2.93</entry><entry>3.7</entry></row><row><entry>31.09</entry><entry>2.87</entry><entry>3.1</entry></row><row><entry>31.36</entry><entry>2.85</entry><entry>0.8</entry></row><row><entry>31.98</entry><entry>2.80</entry><entry>2.2</entry></row><row><entry>32.23</entry><entry>2.78</entry><entry>1.7</entry></row><row><entry>32.37</entry><entry>2.76</entry><entry>0.6</entry></row><row><entry>32.64</entry><entry>2.74</entry><entry>1.5</entry></row><row><entry>33.03</entry><entry>2.71</entry><entry>0.1</entry></row><row><entry>33.34</entry><entry>2.69</entry><entry>1.0</entry></row><row><entry>33.47</entry><entry>2.68</entry><entry>1.3</entry></row><row><entry>34.08</entry><entry>2.63</entry><entry>0.7</entry></row><row><entry>34.55</entry><entry>2.59</entry><entry>1.8</entry></row><row><entry>34.73</entry><entry>2.58</entry><entry>0.4</entry></row><row><entry namest="1" nameend="3" align="center" rowsep="1" /></row><row><entry namest="1" nameend="3" align="left" id="FOO-00003">^(a)± 0.1</entry></row></tbody></tgroup></table></tables>

After calcination, the X-ray powder diffraction pattern for SSZ-74 exhibits the characteristic lines shown in Table II below.

<tables id="TABLE-US-00005" num="00005"><table frame="none" colsep="0" rowsep="0"><tgroup align="left" colsep="0" rowsep="0" cols="1"><colspec colname="1" colwidth="217pt" align="center" /><thead><row><entry namest="1" nameend="1" rowsep="1">TABLE II</entry></row></thead><tbody valign="top"><row><entry namest="1" nameend="1" align="center" rowsep="1" /></row><row><entry>Calcined SSZ-74</entry></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="1" colwidth="63pt" align="center" /><colspec colname="2" colwidth="70pt" align="center" /><colspec colname="3" colwidth="84pt" align="center" /><tbody valign="top"><row><entry /><entry /><entry>Relative Integrated</entry></row><row><entry>2 Theta^(a)</entry><entry>d-spacing (Angstroms)</entry><entry>Intensity (%)</entry></row><row><entry namest="1" nameend="3" align="center" rowsep="1" /></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="1" colwidth="63pt" align="char" char="." /><colspec colname="2" colwidth="70pt" align="char" char="." /><colspec colname="3" colwidth="84pt" align="center" /><tbody valign="top"><row><entry>7.98</entry><entry>11.07</entry><entry>M</entry></row><row><entry>8.30</entry><entry>10.16</entry><entry>VS</entry></row><row><entry>8.89</entry><entry>9.93</entry><entry>S</entry></row><row><entry>9.08</entry><entry>9.74</entry><entry>S</entry></row><row><entry>14.02</entry><entry>6.31</entry><entry>W</entry></row><row><entry>14.93</entry><entry>5.93</entry><entry>M</entry></row><row><entry>16.03</entry><entry>5.52</entry><entry>M</entry></row><row><entry>23.26</entry><entry>3.82</entry><entry>VS</entry></row><row><entry>23.95</entry><entry>3.71</entry><entry>W</entry></row><row><entry>24.08</entry><entry>3.69</entry><entry>M</entry></row><row><entry namest="1" nameend="3" align="center" rowsep="1" /></row><row><entry namest="1" nameend="3" align="left" id="FOO-00004">^(a)± 0.1</entry></row></tbody></tgroup></table></tables>

Table IIA below shows the X-ray powder diffraction lines for calcined SSZ-74 including actual relative intensities.

<tables id="TABLE-US-00006" num="00006"><table frame="none" colsep="0" rowsep="0"><tgroup align="left" colsep="0" rowsep="0" cols="1"><colspec colname="1" colwidth="217pt" align="center" /><thead><row><entry namest="1" nameend="1" rowsep="1">TABLE IA</entry></row></thead><tbody valign="top"><row><entry namest="1" nameend="1" align="center" rowsep="1" /></row><row><entry>Calcined SSZ-74</entry></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="1" colwidth="63pt" align="center" /><colspec colname="2" colwidth="70pt" align="center" /><colspec colname="3" colwidth="84pt" align="center" /><tbody valign="top"><row><entry /><entry /><entry>Relative Integrated</entry></row><row><entry>2 Theta^(a)</entry><entry>d-spacing (Angstroms)</entry><entry>Intensity (%)</entry></row><row><entry namest="1" nameend="3" align="center" rowsep="1" /></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="1" colwidth="63pt" align="char" char="." /><colspec colname="2" colwidth="70pt" align="char" char="." /><colspec colname="3" colwidth="84pt" align="char" char="." /><tbody valign="top"><row><entry>7.98</entry><entry>11.07</entry><entry>34.9</entry></row><row><entry>8.70</entry><entry>10.16</entry><entry>86.8</entry></row><row><entry>8.89</entry><entry>9.93</entry><entry>40.2</entry></row><row><entry>9.08</entry><entry>9.74</entry><entry>47.0</entry></row><row><entry>9.66</entry><entry>9.15</entry><entry>1.0</entry></row><row><entry>11.26</entry><entry>7.85</entry><entry>0.4</entry></row><row><entry>11.34</entry><entry>7.80</entry><entry>0.5</entry></row><row><entry>12.76</entry><entry>6.93</entry><entry>1.1</entry></row><row><entry>13.26</entry><entry>6.67</entry><entry>4.6</entry></row><row><entry>14.02</entry><entry>6.31</entry><entry>13.4</entry></row><row><entry>14.93</entry><entry>5.93</entry><entry>20.9</entry></row><row><entry>16.03</entry><entry>5.52</entry><entry>23.5</entry></row><row><entry>16.39</entry><entry>5.40</entry><entry>4.3</entry></row><row><entry>16.61</entry><entry>5.33</entry><entry>4.4</entry></row><row><entry>17.12</entry><entry>5.18</entry><entry>3.0</entry></row><row><entry>17.80</entry><entry>4.98</entry><entry>2.8</entry></row><row><entry>18.19</entry><entry>4.87</entry><entry>7.6</entry></row><row><entry>19.05</entry><entry>4.66</entry><entry>1.9</entry></row><row><entry>19.74</entry><entry>4.49</entry><entry>0.4</entry></row><row><entry>20.44</entry><entry>4.34</entry><entry>3.0</entry></row><row><entry>20.75</entry><entry>4.28</entry><entry>3.4</entry></row><row><entry>21.19</entry><entry>4.19</entry><entry>7.7</entry></row><row><entry>21.67</entry><entry>4.10</entry><entry>4.1</entry></row><row><entry>21.99</entry><entry>4.04</entry><entry>5.8</entry></row><row><entry>22.68</entry><entry>3.92</entry><entry>3.7</entry></row><row><entry>22.79</entry><entry>3.90</entry><entry>9.5</entry></row><row><entry>23.26</entry><entry>3.82</entry><entry>100.0</entry></row><row><entry>23.95</entry><entry>3.71</entry><entry>14.2</entry></row><row><entry namest="1" nameend="3" align="center" rowsep="1" /></row><row><entry namest="1" nameend="3" align="left" id="FOO-00005">^(a)± 0.1</entry></row></tbody></tgroup></table></tables>

The X-ray powder diffraction patterns were determined by standard techniques. The radiation was the K-alpha/doublet of copper. The peak heights and the positions, as a function of 2θ where θ is the Bragg angle, were read from the relative intensities of the peaks, and d, the interplanar spacing in Angstroms corresponding to the recorded lines, can be calculated.

The variation in the scattering angle (two theta) measurements, due to instrument error and to differences between individual samples, is estimated at ±0.1 degrees.

Representative peaks from the X-ray diffraction pattern of calcined SSZ-74 are shown in Table II. Calcination can result in changes in the intensities of the peaks as compared to patterns of the “as-made” material, as well as minor shifts in the diffraction pattern.

Crystalline SSZ-74 can be used as-synthesized, but preferably will be thermally treated (calcined). Usually, it is desirable to remove the alkali metal cation (if any) by ion exchange and replace it with hydrogen, ammonium, or any desired metal ion.

SSZ-74 can be formed into a wide variety Of physical shapes. Generally speaking, the molecular sieve can be in the form of a powder, a granule, or a molded product, such as extrudate having a particle size sufficient to pass through a 2-mesh (Tyler) screen and be retained on a 400-mesh (Tyler) screen. In cases where the catalyst is molded, such as by extrusion with an organic binder, the SSZ-74 can be extruded before drying, or, dried or partially dried and then extruded.

SSZ-74 can be composited with other materials resistant to the temperatures and other conditions employed in organic conversion processes. Such matrix materials include active and inactive materials and synthetic or naturally occurring zeolites as well as inorganic materials such as clays, silica and metal oxides. Examples of such materials and the manner in which they can be used are disclosed in U.S. Pat. No. 4,910,006, issued May 20, 1990 to Zones et al., and U.S. Pat. No. 5,316,753, issued May 31, 1994 to Nakagawa, both of which are incorporated by reference herein in their entirety.

EXAMPLES

The following examples demonstrate but do not limit the present invention.

Example 1

Synthesis of Hexamethylene-1,6-bis-(N-methyl-N-pyrrolidinium) dication SDA

In 50 ml of acetone was dissolved 5 ml (48 mmoles) of N-methyl pyrrolidine. 4.9 Grams of 1,6 dibromohexane (20 mmoles) were added and the resulting mixture was stirred at room temperature for three days. Solids formed and were collected by filtration and washed with ether and kept in a vacuum oven. Then 3.71 grams of the dried solid was mixed into 18.7 grams of water and 9.57 grams of AG1-X8 resin for exchange to the OH form. The exchange was run overnight and then the solution was collected and titrated.

Example 2

Synthesis of All-Silica SSZ-74

6.4 Grams of the solution from Example 1 (3 mmoles) was mixed in a tared Teflon cup with 1.26 grams of tetraethyl orthosilicate and then allowed to evaporate (in a hood) for several days as hydrolysis occurred. A second reaction was set up the same way. After evaporation to the appearance of dryness, one reaction was given 0.20 gram of water and mixed. The second was given 0.60 gram of water and the same treatment ensued. 0.125 Gram of about 50% HF was carefully added to each reaction mixture and the contents were stirred with a plastic spatula and a thick gel formed. In the first case the H2O/SiO2 ratio was now roughly 3.5 and it was 7.0 in the second case. The materials were heated to 150° C. and at 43 RPM in tumbled Parr reactors placed in a Blue M convection heating oven. The reactions were cooled and opened in 6 day periods with a small amount examined by Scanning Electron Microscopy to determine if crystals had formed. After 22 days there was crystalline material in both and the solids were collected (filtration) and washed With copious amounts of water, air dried and then examined by X-ray diffraction (XRD). The product in both cases was 557-74.

Example 3

Calcination of SSZ-74

The products from both reactions in Example 2 were calcined in stages and in air to 595° C. to remove the organic content. The materials were found to be stable and the XRD patterns showed the relationship to the as-made SSZ-74.

Example 4

Adsorption of 2,2-Dimethylbutane

The calcined material of Example 3 was then tested for the uptake of the hydrocarbon 2,2-dimethylbutane. This adsorbate does not enter small pore zeolites (8-ring portals) and sometimes is hindered in entering intermediate pore zeolites like ZSM-5. The SSZ-74 showed a profile more characteristic of intermediate pore materials (as contrasted to Y zeolite, a large pore material), showing steady gradual uptake of the adsorbate.

SSZ-74 was shown to adsorb about 0.08 cc/gram after 3 hours of exposure to the 2,2 dimethyl butane adsorbate using a pulsed mode. This value compares with an analysis for ZSM-5 zeolite which gives a value closer to 0.07 cc/gm at the same point in time under the same experimental conditions. This would indicate that the pores of SSZ-74 are at least 10-rings

Example 5

Synthesis of Aluminosilicate SSZ-74

The synthesis parameters of Example 2 were repeated except for the following changes. (1) 0.04 gram of Y zeolite material LZ-210 was added as a potential contributor of Al; (2) the initial H2O/SiO2 ratio for the synthesis was adjusted to 5; (3) seeds of a successful SSZ-74 product were added; and (4) the reaction was run at 170° C. After 9 days there was crystalline material which was SSZ-74 when worked up and analyzed by XRD. The solids were calcined then as in Example 3.

Example 6

Constraint Index

0.12 grams of the material from Example 5, in a 20-40 pelleted and meshed range, was loaded into a stainless steel reactor and run in a Constraint Index test (50/50 n-hexane/3-methylpentane). The normal feed rate was used (8 μl/min.) and the test was run at 700° F. after the catalyst had been dried in the reactor to near 1000° F. Helium flow as used. At 10 minutes on-stream nearly 30% of the feed was being converted with about equal amounts of each reactant. The selectivity did not change as the catalyst fouled to half the conversion at 100 minutes. The pores of the active SSZ-74 were at least intermediate in size.

Example 7

Synthesis of Aluminosilicate SSZ-74

Three mMoles of SDA solution and 1.26 grams (6 mMoles) of tetraethylorthosilicate were combined in a Teflon cup for a Parr reactor. The contents were allowed to react and then most of the water and then the ethanol by-product were allowed to evaporate in a hood over several days. Once the H2O/SiO2 ratio was about 5, from the evaporation, 0.04 grams of LZ-210 zeolite were added (LZ-210 is a Y zeolite which has been treated with (NH₄⁺)₂SiF₆to provide some de-alumination). A few mg of seeds of SSZ-74 were added in the as-made state. Lastly, 0.132 gram of 50% HF was added and the reactor was closed up and heated at 170° C., 43 RPM, for six days. A sample of the cooled reaction product showed nicely crystalline material in an electron microscope. The reaction contents were worked up and dried. Analysis by X-ray diffraction showed the product to be molecular sieve SSZ-74.

The sample was calcined (in air to 595° C.) and then pelleted and meshed (20-40) and run in a standard Constraint Index test. At 700° F. the initial conversion was 28% with a CI value of 1.1. With time-on-stream the catalyst showed a steady deactivation while the CI value did not change much.